Convert dotx or docx to pdf with Word Automation Service failed

Hello everybody,
After search on the internet, I'm looking for a solution to this issue.
I wrote this code for a document conversion in a visual studio 2010 workflow:
string wordAutomationServiceName = "Word Automation Service";
ConversionJobSettings jobSettings = new ConversionJobSettings();
jobSettings.OutputFormat = SaveFormat.PDF;
ConversionJob job = new ConversionJob(wordAutomationServiceName, jobSettings);
job.UserToken = workflowProperties.Site.UserToken;
job.AddFile(workflowProperties.WebUrl + "/" + file.Url,
workflowProperties.WebUrl + "/" + file.Url.Replace(".docx", ".pdf"));
job.Start();
URLs are corrects and the word document exists.
The problem is when the job is executed, I have errors in SharePoint logs:
11/18/2011 09:24:15.87     w3wp.exe (0x1BC4)                           0x1CA0    Word Automation Services     
    Office Viewing Architecture       9rte    Medium      Request received for document 00000001-0001-10e2-80af-d08c970b9892, format: , numberInQueue: 0, request id ba03fb58-55b2-4c6c-b1ca-20fad3b11585   
00000001-0001-10e2-80af-d08c970b9892
11/18/2011 09:24:15.87     w3wp.exe (0x1BC4)                           0x1CA0    Word Automation Services     
    Office Viewing Architecture       c7ld    Medium      AppManager.BeginProcessRequest adding request to queue    00000001-0001-10e2-80af-d08c970b9892
11/18/2011 09:24:15.88     w3wp.exe (0x1BC4)                           0x1CA0    Word Automation Services     
    Timer Job                         g27p    Medium      Local Controller '71cf62b9-c34c-46c4-9828-55de2d5f5ac0':
In Progress: <http://site/Contracts/docsettest/contracttest.dotx> downloaded and queued locally    00000001-0001-10e2-80af-d08c970b9892
11/18/2011 09:24:15.88     w3wp.exe (0x1BC4)                           0x17C0    Word Automation Services     
    Configuration                     g6xc    Medium      Item 00000001-0001-10e2-80af-d08c970b9892: Assigned to
local worker process: 1D64 (7524; worker id = cce33245-48b9-4b0d-afcd-e3218845d81a)    00000001-0001-10e2-80af-d08c970b9892
11/18/2011 09:24:15.88     w3wp.exe (0x1BC4)                           0x1CA0    SharePoint Foundation        
    Monitoring                        b4ly    Medium      Leaving Monitored Scope (ExecuteWcfServerOperation).
Execution Time=23.6994391735768    2fd2393d-f36d-49a1-bfdf-737aefc8659a
11/18/2011 09:24:15.88     w3wp.exe (0x1BC4)                           0x211C    Word Automation Services     
    Office Viewing Architecture       vipp    Medium      AppWorker:cce33245-48b9-4b0d-afcd-e3218845d81a initializing for request ba03fb58-55b2-4c6c-b1ca-20fad3b11585   
00000001-0001-10e2-80af-d08c970b9892
11/18/2011 09:24:15.88     w3wp.exe (0x1BC4)                           0x211C    Word Automation Services     
    Office Viewing Architecture       vipr    Monitorable    AppWorker:cce33245-48b9-4b0d-afcd-e3218845d81a worker call failed System.ServiceModel.CommunicationObjectAbortedException: The
communication object, System.ServiceModel.Channels.ServiceChannel, cannot be used for communication because it has been Aborted.    Server stack trace:      at System.ServiceModel.Channels.CommunicationObject.ThrowIfDisposedOrNotOpen()    
at System.ServiceModel.Channels.ServiceChannel.Call(String action, Boolean oneway, ProxyOperationRuntime operation, Object[] ins, Object[] outs, TimeSpan timeout)     at System.ServiceModel.Channels.ServiceChannelProxy.InvokeService(IMethodCallMessage
methodCall, ProxyOperationRuntime operation)     at System.ServiceModel.Channels.ServiceChannelProxy.Invoke(IMessage message)    Exception rethrown at [0]:      at System.Runtime.Re...   
00000001-0001-10e2-80af-d08c970b9892
11/18/2011 09:24:15.88*    w3wp.exe (0x1BC4)                           0x211C    Word Automation Services     
    Office Viewing Architecture       vipr    Monitorable    ...moting.Proxies.RealProxy.HandleReturnMessage(IMessage reqMsg, IMessage retMsg)     at System.Runtime.Remoting.Proxies.RealProxy.PrivateInvoke(MessageData&
msgData, Int32 type)     at Microsoft.Office.Web.Conversion.Framework.Remoting.IAppChannelCallback.Initialize(WorkerRequest request, FileItem fileItem)     at Microsoft.Office.Web.Conversion.Framework.AppWorker.ProcessRequest(ConversionRequest
request). Worker name WordAutomationServices, Document 00000001-0001-10e2-80af-d08c970b9892    00000001-0001-10e2-80af-d08c970b9892
11/18/2011 09:24:15.88     w3wp.exe (0x1BC4)                           0x211C    Word Automation Services     
    Service                           g281    Medium      Local Controller '71cf62b9-c34c-46c4-9828-55de2d5f5ac0':
Failure: <http://site/Contracts/docsettest/contracttest.dotx> not uploaded to <http://site/Contracts/docsettest/contracttest.pdf> (65543)    00000001-0001-10e2-80af-d08c970b9892
11/18/2011 09:24:15.90     w3wp.exe (0x1BC4)                           0x211C    Word Automation Services     
    Office Viewing Architecture       c78j    Unexpected    AppWorker:cce33245-48b9-4b0d-afcd-e3218845d81a ProcessRequestDone() received error response WorkerException, restarting the worker   
00000001-0001-10e2-80af-d08c970b9892
11/18/2011 09:24:15.90     w3wp.exe (0x1BC4)                           0x211C    Word Automation Services     
    Office Viewing Architecture       b1qa    Medium      Shutting down process with force processId: 7524 belonging to AppWorker cce33245-48b9-4b0d-afcd-e3218845d81a   
00000001-0001-10e2-80af-d08c970b9892
11/18/2011 09:24:15.91     w3wp.exe (0x1BC4)                           0x1CA0    Word Automation Services     
    Configuration                     g6xb    Medium      Local Controller '71cf62b9-c34c-46c4-9828-55de2d5f5ac0':
Local worker process exited: 1D64 (7524); exit time = 11/18/2011 09:24:15     
11/18/2011 09:24:15.91     w3wp.exe (0x1BC4)                           0x1CA0    Word Automation Services     
    Configuration                     d0md    Medium      App 'Word Automation Service': Deleting temp directory
'C:\Windows\TEMP\wdsrv\21659d2e-c634-46a2-9585-b4cd1398f64c\odsibdmm.cmv\1D64'     
11/18/2011 09:24:15.92     w3wp.exe (0x1BC4)                           0x211C    Word Automation Services     
    Office Viewing Architecture       xpre    Medium      Removing worker cce33245-48b9-4b0d-afcd-e3218845d81a, thread: 216    00000001-0001-10e2-80af-d08c970b9892
11/18/2011 09:24:15.92     w3wp.exe (0x1BC4)                           0x211C    Word Automation Services     
    Office Viewing Architecture       f2yg    Medium      CreateSandBoxedProcessWorker() is called    00000001-0001-10e2-80af-d08c970b9892
11/18/2011 09:24:15.93     w3wp.exe (0x1BC4)                           0x211C    Word Automation Services     
    Office Viewing Architecture       b10e    Medium      Created desktop: Service-0x0-3eaf55d$\Microsoft Office Isolated Environment     00000001-0001-10e2-80af-d08c970b9892
11/18/2011 09:24:15.93     w3wp.exe (0x1BC4)                           0x211C    Word Automation Services     
    Office Viewing Architecture       2brt    Medium      AppWorker:89d80fff-43ec-459e-9d95-5ed8b67f20bb worker process is started Exe: WordServerWorker.exe Args: /id 89d80fff-43ec-459e-9d95-5ed8b67f20bb
/convertingService net.pipe://127.0.0.1/WordServer71cf62b9-c34c-46c4-9828-55de2d5f5ac0 /assembly WdsrvWorker.dll /type WACWS /IsBatchedTracing True /LogQuota 100 WorkerType: WorkerType1 Directory: c:\windows\system32\inetsrv, pid : 3700, IsSandBoxed: True,
UniqueSandBoxSid: S-1-5-26473-19571-45394-48    00000001-0001-10e2-80af-d08c970b9892
11/18/2011 09:24:15.93     w3wp.exe (0x1BC4)                           0x211C    Word Automation Services     
    Office Viewing Architecture       vioz    Medium      RemoveWorker isRemoved: True session id : uuid:c9cce13b-5285-47d6-a666-29da19e57c67;id=47, Guid: cce33245-48b9-4b0d-afcd-e3218845d81a   
00000001-0001-10e2-80af-d08c970b9892
11/18/2011 09:24:15.93     w3wp.exe (0x1BC4)                           0x211C    Word Automation Services     
    Office Viewing Architecture       b4em    Monitorable    AppWorker:cce33245-48b9-4b0d-afcd-e3218845d81a recycle worker process because the conversion failed with result WorkerException.
Worker is WordAutomationServices    00000001-0001-10e2-80af-d08c970b9892
11/18/2011 09:24:15.93     w3wp.exe (0x1BC4)                           0x211C    Word Automation Services     
    Office Viewing Architecture       xpre    Medium      Removing worker cce33245-48b9-4b0d-afcd-e3218845d81a, thread: 216    00000001-0001-10e2-80af-d08c970b9892
11/18/2011 09:24:15.93     w3wp.exe (0x1BC4)                           0x211C    Word Automation Services     
    Office Viewing Architecture       vioz    Medium      RemoveWorker isRemoved: False session id : uuid:c9cce13b-5285-47d6-a666-29da19e57c67;id=47, Guid: cce33245-48b9-4b0d-afcd-e3218845d81a   
00000001-0001-10e2-80af-d08c970b9892
11/18/2011 09:24:15.93     w3wp.exe (0x1BC4)                           0x211C    Word Automation Services     
    Office Viewing Architecture       a2oj    Medium      PreProcessTime = 0; InConversionQueueTime = 0.0019142; ResponseTime = 0.0066997; TotalConversionTime = 0.0535976; AvgPreProcessTime
= 0; AvgInConversionQueueTime = 0; AvgResponseTime = 0; AvgTotalConversionTime = 0; historyCount = 0; result = WorkerException; format = n/a    00000001-0001-10e2-80af-d08c970b9892
11/18/2011 09:24:15.93     w3wp.exe (0x1BC4)                           0x144C    Word Automation Services     
    Office Viewing Architecture       4sig    Medium      ChildProcess WordServerWorker.exe is launched inside worker 89d80fff-43ec-459e-9d95-5ed8b67f20bb. Pid 3700   
11/18/2011 09:24:15.93     w3wp.exe (0x1BC4)                           0x144C    Word Automation Services     
    Office Viewing Architecture       d9hn    Medium      NotifyNewChildProcessInWorker has seen WordServerWorker.exe in worker 89d80fff-43ec-459e-9d95-5ed8b67f20bb   
11/18/2011 09:24:16.45     w3wp.exe (0x1BC4)                           0x18CC    Word Automation Services     
    Office Viewing Architecture       viou    Medium      ... registering worker 89d80fff-43ec-459e-9d95-5ed8b67f20bb     
11/18/2011 09:24:16.48     w3wp.exe (0x1BC4)                           0x18CC    Word Automation Services     
    Office Viewing Architecture       viox    Medium      Worker 89d80fff-43ec-459e-9d95-5ed8b67f20bb is now initialized.     
11/18/2011 09:24:16.55     w3wp.exe (0x1BC4)                           0x18CC    Word Automation Services     
    Office Viewing Architecture       vipx    Monitorable    AppWorker:89d80fff-43ec-459e-9d95-5ed8b67f20bb application server host exited unexpectedly  (thread: 6)   
11/18/2011 09:24:16.55     w3wp.exe (0x1BC4)                           0x18CC    Word Automation Services     
    Office Viewing Architecture       c78j    Unexpected    AppWorker:89d80fff-43ec-459e-9d95-5ed8b67f20bb ProcessRequestDone() received error response WorkerCrashed, restarting the worker   
11/18/2011 09:24:16.57     w3wp.exe (0x1BC4)                           0x18CC    Word Automation Services     
    Office Viewing Architecture       xpre    Medium      Removing worker 89d80fff-43ec-459e-9d95-5ed8b67f20bb, thread: 6     
11/18/2011 09:24:16.57     w3wp.exe (0x1BC4)                           0x18CC    Word Automation Services     
    Office Viewing Architecture       f2yg    Medium      CreateSandBoxedProcessWorker() is called     
11/18/2011 09:24:16.57     w3wp.exe (0x1BC4)                           0x18CC    Word Automation Services     
    Office Viewing Architecture       b10e    Medium      Created desktop: Service-0x0-3eb1722$\Microsoft Office Isolated Environment      
11/18/2011 09:24:16.57     w3wp.exe (0x1BC4)                           0x18CC    Word Automation Services     
    Office Viewing Architecture       2brt    Medium      AppWorker:59168d75-7086-4318-8d12-633affa7b783 worker process is started Exe: WordServerWorker.exe Args: /id 59168d75-7086-4318-8d12-633affa7b783
/convertingService net.pipe://127.0.0.1/WordServer71cf62b9-c34c-46c4-9828-55de2d5f5ac0 /assembly WdsrvWorker.dll /type WACWS /IsBatchedTracing True /LogQuota 100 WorkerType: WorkerType1 Directory: c:\windows\system32\inetsrv, pid : 6752, IsSandBoxed: True,
UniqueSandBoxSid: S-1-5-26473-19571-45394-49     
11/18/2011 09:24:16.57     w3wp.exe (0x1BC4)                           0x18CC    Word Automation Services     
    Office Viewing Architecture       vioz    Medium      RemoveWorker isRemoved: True session id : uuid:c9cce13b-5285-47d6-a666-29da19e57c67;id=48, Guid: 89d80fff-43ec-459e-9d95-5ed8b67f20bb   
11/18/2011 09:24:16.57     w3wp.exe (0x1BC4)                           0x144C    Word Automation Services     
    Office Viewing Architecture       4sig    Medium      ChildProcess WordServerWorker.exe is launched inside worker 59168d75-7086-4318-8d12-633affa7b783. Pid 6752   
11/18/2011 09:24:16.57     w3wp.exe (0x1BC4)                           0x144C    Word Automation Services     
    Office Viewing Architecture       d9hn    Medium      NotifyNewChildProcessInWorker has seen WordServerWorker.exe in worker 59168d75-7086-4318-8d12-633affa7b783   
11/18/2011 09:24:17.10     w3wp.exe (0x1BC4)                           0x1CA0    Word Automation Services     
    Office Viewing Architecture       viou    Medium      ... registering worker 59168d75-7086-4318-8d12-633affa7b783     
11/18/2011 09:24:17.13     w3wp.exe (0x1BC4)                           0x1CA0    Word Automation Services     
    Office Viewing Architecture       viox    Medium      Worker 59168d75-7086-4318-8d12-633affa7b783 is now initialized.   
Thank you for your help.

Hi Jean,
Were you able to resolve this?  I am coming across the exact same error on a SharePoint 2010 development machine.  I don't see any other posts on the web about it.  Here is the entry from my ULS logs:
Local Controller 'fc8b8704-f0f1-4e85-a69a-dc5686c27e39': Failure: <http://ip-0a6ee272/Shared%20Documents/Word/hello.docx> not uploaded to <http://ip-0a6ee272/Shared%20Documents/PDF/hello.pdf>
(65543)
Do we share any of the following configuration points?  I'm trying to narrow down the potential root cause ...
MSDN subscriber EXE install media "SharePoint Server 2010 with Service Pack 1 (x64) - (English)"
SP1 slipstream patch level.  No cumulative updates.
http://autospinstaller.codeplex.com/  PowerShell scripted install
SQL 2008 R2 installed on same box as SharePoint
Active Directory domain controller on same box as SharePoint
c:\Windows\System32\drivers\etc\HOSTS file 127.0.0.1 entry for both machine and domain name
Thanks in advance for the research. 
I've actually tried re-installing SharePoint several times on brand new virtual machines.  That did not resolve the issue.  Strangely enough, the RTM version of SharePoint appears to work just fine.  With all other configuration points the
same, I loaded RTM ... ran a Word Automation PowerShell script ... and received the expected PDF output.  Then when I apply the SP1 patch ... it stops working and I get error 65543.
Best,
  @SPJeff

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